$83M
Revenue increase with no additional capital investment
Unlocking Hidden Factory Potential for Growth: Driving Growth Without Capital Investment Through Data-Driven Performance Management
Industry: Chemicals
Service: Manufacturing
Service: Operations Strategy and Transformation
Our Client
A global chemical manufacturer facing capacity constraints and plateauing performance despite sold-out product lines.
The Challenge
The company faced a paradox of success: continuous demand growth but no room for capacity expansion.
- Misleading KPIs: Efficiency losses hidden behind “green” performance indicators.
- Status quo mindset: Focused on maintaining results instead of driving improvement.
- Lack of structured reviews: Performance discussions were reactive and inconsistent.
- Cultural resistance: Limited transparency and reluctance to set ambitious targets.
Real Results Achieved Together
The new performance management system uncovered significant hidden capacity and unlocked growth.
+10%
Improvement in gross margin, driven by efficiency gains
>98%
Schedule attainment (OTIF), up from 85%
Transformation Impact
- Employee engagement score rose from 3.4 to 4.5
- Established a culture of continuous improvement and performance excellence
- Exposed hidden capacity through data-driven performance insights
- Linked KPIs to profitability and operational outcomes
- Improved collaboration and accountability across all organizational levels
- Shifted focus from maintenance of status quo to measurable performance growth
Our Approach
EFESO implemented a world-class performance management system built on three pillars:
KPI Redesign and Alignment
- Defined relevant KPIs at every level — from operations to executive.
- Connected metrics directly to margin and profitability.
- Challenged existing targets to drive real improvement.
Structured Management Cadence
- Introduced three-tier performance reviews: daily, mid-term, and strategic.
- Built visual, data-driven processes to enable proactive decisions.
Embedding Continuous Improvement Culture
- Linked KPIs to compensation and accountability systems.
- Fostered a transparent and ambitious performance culture.
- Enabled managers to identify and unlock the “Hidden Factory.”
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Ready to Unlock Hidden Capacity and Growth?
- Experiencing high demand but constrained capacity?
- Relying on outdated KPIs that mask inefficiencies?
- Seeking to boost performance without major investments?
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